JP7549535B2 - Floorboards with cores containing calcium carbonate and methods for their manufacture - Google Patents

Description

The present disclosure relates to floorboards and methods for their manufacture. In particular, it relates to floorboards having a core comprising calcium carbonate.

There is a great demand in the market for waterproof hardwood floors that are easy to install. US 2017/217133, for example, discloses flooring having a core with a wood veneer attached thereon. However, wood is an organic hygroscopic compound that needs to be protected from heat, moisture, and water. For example, wood and wood-based materials are susceptible to structural and aesthetic damage from heat, water, fungal decay, and mold. Due to its various uses, wood must be protected from insects, fungi, and other organisms. Insects such as termites, beetles, and carpenter ants can cause extensive and costly damage to wood structures. If left unprotected or unpreserved, wood will rot and deteriorate within a period of months to years, depending on the climate and soil conditions. For example, one concern with commercially available flooring is the water and moisture resistance of the final product and the sensitivity of the raw wood to heat, water, and moisture after installation. For example, excess moisture can cause floorboard edge peaking due to expansion, and such edge peaking can lead to chipping and premature wear of the floorboard edges.

For example, moisture sensitivity makes people hesitant to install wood flooring in areas where there will be water on the floor surface, such as kitchens and bathroom areas.

To prevent these effects, it is necessary to protect the wood so that it can be installed in any area and a product can be made that is able to overcome all the above mentioned situations and other disadvantages.

US Patent Application Publication No. 2017/217133

For example, if a wood board does not react to heat and water, it can be installed in an adhesive-free system, simplifying installation of the product and reducing its cost.

SUMMARY OF THE DISCLOSURE According to one aspect, the present disclosure relates to a floorboard having a core, the core comprising at least 50 wt.% calcium carbonate by weight, a first wood veneer having a first grain orientation and secured to one surface of the core, and a second wood veneer having a second grain orientation and secured over the first wood veneer.

According to another aspect, the present disclosure relates to a floorboard having a core comprising at least 50 wt. % calcium carbonate by weight and at least one wood veneer secured to one surface of the core, the at least one veneer comprising about 55 to about 90% veneer resin by weight based on the total weight of the veneer.

According to another aspect, the present disclosure relates to a floorboard having a core comprising at least 50 wt. % calcium carbonate by weight, at least one wood veneer secured to one surface of the core, and a veneer resin, the floorboard comprising about 55 to about 90% veneer resin by weight based on the total weight of the floorboard.

According to another aspect, the present disclosure relates to a floorboard having a core comprising at least 50.0 wt. % calcium carbonate by weight based on the total weight of the core and at least 10.0 wt. % core resin by weight based on ^the total weight of said core, said core having a density of at least 1000 kg/ m3 , and at least one wood veneer fixed to one surface of said core.

In another aspect, the disclosure relates to a method for manufacturing a board, the method comprising the steps of processing a composition including calcium carbonate and a core resin into the shape of a core, securing at least one wood veneer having a first grain orientation to at least one surface of the core, and securing a second wood veneer having a second grain orientation over the at least one wood veneer.

In another aspect, the present disclosure relates to a method for manufacturing a board, the method comprising the steps of: fastening at least one wood veneer having a first grain orientation to at least one surface of a core comprising calcium carbonate and a core resin; and fastening a second wood veneer having a second grain orientation over the at least one wood veneer.

According to another aspect, the present disclosure relates to a method for manufacturing a board comprising the steps of applying a veneer resin onto a surface of a core comprising calcium carbonate and a core resin, contacting a first surface of at least one wood veneer with the veneer resin to fix the at least one wood veneer to the core and impregnating the at least one wood veneer with the veneer resin for a time of about 30 to about 90 minutes/mm thickness of veneer.

According to another aspect, the disclosure relates to a method for manufacturing a board comprising the steps of applying a veneer resin onto a surface of a core comprising calcium carbonate and a core resin; contacting a first surface of at least one wood veneer with the veneer resin to fix the at least one wood veneer to the core and impregnating the at least one wood veneer with the veneer resin for a time period of about 30 to about 90 minutes/mm thickness of veneer; applying the veneer resin to a second surface of the at least one veneer; and contacting a first surface of a second wood veneer with the veneer resin on the second surface of the at least one wood veneer to fix the second wood veneer to the at least one veneer and impregnating the second wood veneer with the veneer resin for a time period of about 30 to about 90 minutes/mm thickness of veneer.

According to another aspect, the present disclosure relates to a floorboard having a core, the core comprising at least 50 wt. % calcium carbonate by weight.

According to another aspect, the present disclosure relates to a floorboard having a core comprising at least 50 wt. % calcium carbonate and a wood veneer applied to one surface of the core.

According to another aspect, the present disclosure relates to a floorboard having a core comprising at least 50 wt. % calcium carbonate, a first wood veneer secured to one surface of the core, and a second wood veneer secured over the first wood veneer.

According to another aspect, a method for manufacturing a board includes processing a composition including calcium carbonate and a core resin into the shape of a core, and securing at least one wood veneer to at least one surface of the core.

Examples of the present disclosure are shown, by way of example only, in the following figures:

1 shows a schematic diagram of an embodiment of a floor plate according to at least one embodiment. FIG. 1B is a schematic diagram of the floor plate of FIG. 1A. FIG. 1 shows a schematic diagram of one embodiment of a floor panel according to at least one embodiment. FIG. 1B is a side view of the floor plate of FIG. 1A. FIG. 2 is a schematic diagram of one embodiment of a floor panel according to at least one embodiment. FIG. 2 is a schematic diagram of one embodiment of a floor panel according to at least one embodiment. FIG. 2 is a schematic diagram of one embodiment of a floor panel according to at least one embodiment.

DETAILED DESCRIPTION OF THE DISCLOSURE Other features and advantages will become more readily apparent from the following description of various illustrative, non-limiting embodiments.

Herein, unless otherwise specified, "an embodiment", "embodiments", "the embodiment", "the embodiments", "one or more embodiments", "some embodiments" and "an embodiment" mean "one or more embodiments of the present invention".

Finally, terms of degree such as "substantially," "about," and "approximately" as used herein mean a reasonable amount of deviation from its modifier that does not materially alter the end result. These terms of degree should be construed to include a deviation of at least ±10% from their modifier, unless such deviation negates the meaning of the word they modify.

The terms "including," "having," and variations thereof mean "including but not limited to," unless otherwise noted. A list of items does not imply that all of the items are mutually exclusive, unless otherwise noted. The words "a," "an," and "the" mean "single or multiple," unless otherwise noted.

Additionally, as used herein, the term "and/or" is intended to represent the inclusive OR. That is, for example, "X and/or Y" is intended to mean either X or Y, or both.

As another example, "X, Y and/or Z" is intended to mean X or Y or Z, or any combination thereof.

For example, the floorboard further comprises at least one wood veneer, the wood veneer being secured to one surface of the core.

For example, the first wood grain direction and the second wood grain direction of the floorboard are substantially perpendicular to each other.

For example, the floorboard has a swelling ratio of less than about 0.5%/0.1mm of wood veneer thickness as measured according to EN 13329.

For example, the floorboards have a swelling ratio of less than about 0.4%/0.1mm of wood veneer thickness as measured according to EN 13329.

For example, the floorboards have a swelling ratio of less than about 0.3%/0.1mm of wood veneer thickness as measured according to EN 13329.

For example, the floorboards have a swelling ratio of less than about 0.2%/0.1mm of wood veneer thickness as measured according to EN 13329.

For example, the floorboards have a swelling ratio of less than about 0.1%/0.1mm of wood veneer thickness as measured according to EN 13329.

For example, the floorboards have a swelling ratio of less than about 0.5%/0.1 mm to less than about 0.01%/0.1 mm of the thickness of the wood veneer as measured according to EN 13329.

For example, the floorboards have a swelling ratio of less than about 0.2%/0.1 mm to less than about 0.02%/0.1 mm of the thickness of the wood veneer as measured according to EN 13329.

For example, the floorboards have a swelling ratio of less than about 0.1%/0.1 mm to less than about 0.01%/0.1 mm of the thickness of the wood veneer as measured according to EN 13329.

For example, the at least one veneer comprises about 55 to about 95% veneer resin by weight based on the total weight of the veneer.

For example, the at least one veneer comprises about 60 to about 85% veneer resin by weight based on the total weight of the veneer.

For example, the at least one veneer comprises about 65 to about 80% veneer resin by weight based on the total weight of the veneer.

For example, the at least one veneer comprises about 70 to about 80% veneer resin by weight based on the total weight of the veneer.

For example, the floorboard comprises about 55% to about 90% veneer resin by weight based on the total weight of the board.

For example, the floorboard comprises about 60% to about 85% veneer resin by weight based on the total weight of the board.

For example, the floorboard comprises about 65% to about 85% veneer resin by weight based on the total weight of the board.

For example, the floorboard comprises about 70% to about 80% veneer resin by weight based on the total weight of the board.

For example, the floorboard further comprises at least one wood veneer, the at least one wood veneer being secured to one surface of the core.

For example, the wood veneer is varnished and sandwiched between the core and the varnish.

For example, the floorboard may further include a first wood veneer that is secured to one surface of the core, and may further include a second wood veneer that is secured over the first wood veneer.

For example, the varnish contains non-toxic, hypoallergenic substances.

For example, the varnish contains an isocyanate.

For example, the first wood veneer and the second wood veneer are substantially the same type and thickness, and the first wood veneer and the second wood veneer form cross-links to stabilize the warping of the floorboard.

For example, the second wood veneer is varnished.

For example, the at least one wood veneer has a thickness of about 0.2 mm to about 7 mm.
For example, the at least one wood veneer has a thickness of about 0.5 mm to about 4 mm.
For example, the at least one wood veneer has a thickness of about 1 mm to about 3 mm.
For example, the at least one wood veneer has a thickness of about 0.5 mm to about 1 mm.

For example, the at least one wood veneer is secured to one surface of the core by an adhesive.

For example, at least one wood veneer is secured to one surface of the core by a resin including polyurethane.

For example, the core forms a tongue and groove locking mechanism.

For example, the core may have a longitudinal groove formed on at least one edge of the core and at least one longitudinal tongue formed on at least one other edge of the core.

For example, the core forms a click-lock type locking mechanism.

For example, the core forms a click-lock adhesive-free system on each edge of the core.

For example, the thickness of the core is about 1 mm to 30 mm.
For example, the thickness of the core is about 1 mm to 15 mm.
For example, the core has a thickness of about 1 mm to about 12 mm.
For example, the thickness of the core is about 2 mm to 10 mm.
For example, the thickness of the core is about 3 mm to 8 mm.

For example, the thickness of the core is about 2 mm.
For example, the thickness of the core is about 3 mm.
For example, the thickness of the core is about 6 mm.
For example, the thickness of the core is about 8 mm.

For example, the core has ^a density of at least 1000 kg/ m3 .
For example, the core has ^a density of about 1000 kg/ m3 to about 2600 ^kg / m3 .

For example, the core has ^a density of at least 1500 kg/ m3 .
For example, the core has ^a density of at least 1800 kg/ m3 .
For example, the core has ^a density of about 1800 kg/ m3 .

For example, the core has ^a density of about 1500 kg/ m3 to about 2100 ^kg / m3 .

For example, the core comprises at least 55 wt.% calcium carbonate.
For example, the core comprises at least 60 wt.% calcium carbonate.
For example, the core comprises at least 65 wt.% calcium carbonate.
For example, the core comprises at least 70 wt.% calcium carbonate.
For example, the core comprises at least 75 wt.% calcium carbonate.

For example, the core may have about 50 wt.% to about 90 wt.% calcium carbonate.
For example, the core may have about 60 wt.% to about 80 wt.% calcium carbonate.
For example, the core may have about 65 wt.% to about 75 wt.% calcium carbonate.
For example, the core may have about 68 wt.% to about 72 wt.% calcium carbonate.

For example, the core may have between about 10 wt. % and about 40 wt. % core resin.
For example, the core may have from about 15 wt. % to about 35 wt. % core resin.
For example, the core may have about 20 wt.% to about 30 wt.% core resin.
For example, the core may have about 22 wt.% to about 28 wt.% core resin.
For example, the core may have about 23 wt.% to about 27 wt.% core resin.

For example, the core resin may include polyethylene (PE), polypropylene (PP), high density polyethylene (HDPE), low density polyethylene (LDPE), polyethylene terephthalate (PET), and/or polyvinyl chloride (PVC).

For example, the core resin includes polyvinyl chloride (PVC).

For example, the core resin further includes at least one of color powder, chlorinated polyethylene, polyethylene, and calcium stearate.

For example, the core may include about 65 wt. % to about 75 wt. % calcium carbonate and about 20 wt. % to about 30 wt. % resin.

For example, the core may include about 70 wt. % calcium carbonate and about 25 wt. % PVC resin.

For example, the core may include about 0.1 wt. % to about 1.0 wt. % color powder, about 1 wt. % to about 2 wt. % chlorinated polyethylene, about 1 wt. % to about 2 wt. % polyethylene, and about 0.1 wt. % to about 1.0 wt. % calcium stearate.

For example, the core may include about 0.5 wt. % color powder, about 1.3 wt. % chlorinated polyethylene, about 1.5 wt. % polyethylene, and about 0.6 wt. % calcium stearate.

For example, the core is a panel of at least 1200mm x at least 1200mm.

For example, the core is an extruded panel approximately 1230mm by approximately 1280mm.
For example, the core is an extruded panel approximately 1200mm x approximately 1200mm.
For example, the core is an extruded panel approximately 209 mm by approximately 1230 mm.

For example, the board is waterproof.

For example, the plate is moisture and/or heat resistant.

For example, a method for making a board includes processing a composition including calcium carbonate and a resin into the shape of a core, and securing at least one wood veneer to at least one surface of the core.

For example, the at least one wood veneer and the second wood veneer are fixed such that the first wood grain direction and the second wood grain direction are substantially perpendicular to each other.

For example, the processing step includes extruding the core.

For example, the veneer resin is applied by a roller coater.

For example, the processing step further includes pressing the plate at a temperature of about 40°C to about 100°C. For example, the processing step further includes pressing the plate at a temperature of about 50°C to about 80°C.

For example, the treatment step further includes pressing the plate at a temperature of about 60°C to about 70°C.

For example, the plate may be pressed for a period of time ranging from about 20 minutes to about 60 minutes.
For example, the plate may be pressed for a period of time ranging from about 30 minutes to about 50 minutes.

For example, the veneer resin is applied to the surface of the core in an amount ^of about 80 g to about 160 g/ m2 .

For example, the veneer resin is applied to the surface of the core in an amount ^of about 100 g to about 140 g/ m2 .

For example, the veneer resin is applied to the surface of the core in an amount ^of about 110 g to about 130 g/ m2 .

For example, the veneer resin is applied to the second surface of the at least one veneer in ^an amount of about 40 g to about 80 g/ m2 .

For example, the veneer resin is applied to the second surface of the at least one veneer in ^an amount of about 45 g to about 75 g/ m2 .

For example, the veneer resin is applied to the second surface of the at least one veneer in an amount ^of about 50 g to about 70 g/ m2 .

For example, the veneer resin is applied to the second surface of the at least one veneer in ^an amount of about 50 g to about 60 g/ m2 .

For example, the thickness of the core is about 1 mm to about 12 mm.

For example, the fixing step includes fixing a first wood veneer having a first grain orientation to one surface of the core, and fixing a second wood veneer having a second grain orientation on top of the first wood veneer.

For example, the method may further include applying a first resin layer between the one surface of the core and the first wood veneer to secure the first wood veneer to the core, and applying a second resin layer between the first wood veneer and the second wood veneer to secure the second wood veneer to the first wood veneer, so that the first wood veneer and the second wood veneer form cross links that stabilize the warping of the floorboard.

For example, at least one of the first resin layer and the second resin layer contains polyurethane.

For example, the method may further include at least one of trimming the board, cutting the board, profiling the board, sanding the board, and varnishing the board.

For example, the method may include profiling a locking mechanism on at least one edge of the plate.

For example, the method may include profiling a locking mechanism on each edge of the plate.

For example, the profiling step may include profiling a longitudinal groove on one edge of the core and/or profiling a longitudinal tongue on another edge of the core.

For example, the profiling step includes profiling a click-lock system on each edge of the core.

For example, the profiling step may include profiling a click-lock adhesive-free system on each edge of the core.

For example, the method may further include cutting the plate prior to profiling the plate.

For example, the varnish contains non-toxic, hypoallergenic substances.

For example, the varnish contains an isocyanate.

For example, the varnish includes at least one anti-yellowing UV inhibitor.

Referring to Figure 1A, a schematic diagram of a floor plate 1 is shown. In Figure 1A, said floor plate 1 is shown in the form of a 1280mm x 1230mm panel.

Referring to Figure 1B, another view of the floor plate of Figure 1A is shown.

The floorboard has a core. The core comprises calcium carbonate.

For example, the core has a thickness of about 1 mm to about 12 mm.
For example, the core has a thickness of about 2 mm to about 10 mm.
For example, the core has a thickness of about 3 mm to about 8 mm.

For example, the thickness of the core is about 2 mm.
For example, the thickness of the core is about 3 mm.
For example, the thickness of the core is about 6 mm.
For example, the thickness of the core is about 8 mm.

For example, the core has a density of ^at least 1800 kg/ m3 .
For example, the core has ^a density of about 1000 kg/ m3 to about 2600 ^kg / m3 .

For example, the core has a density of ^at least 1500 kg/ m3 .
For example, the core has ^a density of about 1500 kg/ m3 to about 2100 ^kg / m3 .

For example, the core comprises at least 55 wt. % calcium carbonate.
For example, the core comprises at least 60 wt. % calcium carbonate.
For example, the core comprises at least 65 wt.% calcium carbonate.
For example, the core comprises at least 70 wt.% calcium carbonate.
For example, the core comprises at least 75 wt.% calcium carbonate.

For example, the core may include about 50 wt.% to about 90 wt.% calcium carbonate.
For example, the core may include about 60 wt.% to about 80 wt.% calcium carbonate.
For example, the core may include about 65 wt.% to about 75 wt.% calcium carbonate.
For example, the core may include about 68 wt.% to about 72 wt.% calcium carbonate.

For example, the core may include from about 10 wt. % to about 40 wt. % core resin.
For example, the core may include about 15 wt.% to about 35 wt.% core resin.
For example, the core may include about 20 wt.% to about 30 wt.% core resin.
For example, the core may include about 22 wt.% to about 28 wt.% core resin.
For example, the core may include about 23 wt.% to about 27 wt.% core resin.

For example, the core resin includes polyvinyl chloride (PVC).

For example, the core includes at least one of a color powder, chlorinated polyethylene, polyethylene, and calcium stearate.

For example, the core may include about 70 wt. % calcium carbonate and about 25 wt. % PVC core resin.

For example, the core may include about 70 wt. % calcium carbonate and about 25 wt. % PVC core resin.

For example, the core may include about 0.1 wt. % to about 1.0 wt. % color powder, about 1 wt. % to about 2 wt. % chlorinated polyethylene, about 1 wt. % to about 2 wt. % polyethylene, and about 0.1 wt. % to about 1.0 wt. % calcium stearate.

For example, the core may include about 0.5 wt. % color powder, about 1.3 wt. % chlorinated polyethylene, about 1.5 wt. % polyethylene, and about 0.6 wt. % calcium stearate.

For example, the core may be composed of approximately 70% calcium carbonate and approximately 25% PVC core resin.

For example, the core may be composed of about 0.5% color powder, about 1.3% chlorinated polyethylene, about 1.5% polyethylene, and about 0.6% calcium stearate.

For example, the core can be stable to humidity fluctuations (RH 30%-70%).

For example, the core may provide greater strength over time.

For example, it may be resistant to expansion and/or contraction, such as when atmospheric conditions change.

For example, the core may be heat resistant.
For example, the core may be waterproof.
For example, the core can be rigid.
For example, the core may be dent resistant.

Referring to Figure 2A, a schematic diagram of floor plate 21 is shown.

Referring to Figure 2B, a side view of the floor plate 21 of Figure 2A is shown.

Figure 2B illustrates a mechanical locking system 23. For example, the mechanical locking system 23 can be profiled into the core of the floorboard 21.

For example, the mechanical locking system can be a click-lock adhesive-free system on each edge of the core.

For example, the mechanical locking system can be a tongue and groove system.

For example, the floorboard may include a groove extending along a first edge of the first panel and a tongue extending along a second edge of the first panel.

For example, the tongue may be provided on the opposite side of the edge of the panel that includes the groove.

For example, the groove has a groove profile and the tongue has a tongue profile, and the tongue and groove can be connected to another panel that also has the groove profile and the tongue profile.

For example, the groove of the first panel can be inserted into the tongue of the second panel with the second panel laid flat on a surface to form a mechanical lock.

For example, a flooring board may include a core of calcium carbonate and/or other materials as described above. The flooring board may further include a wood veneer applied onto one surface of the core. The wood veneer may be varnished such that the wood veneer is sandwiched between the core and the varnish.

For example, the varnish may include non-toxic, hypoallergenic materials.

For example, the varnish may contain an isocyanate.

For example, the wood veneer may have a thickness of about 0.2 mm to about 7 mm.

For example, the wood veneer may have a thickness of about 0.5 mm to about 4 mm.

For example, the wood veneer may have a thickness of about 1 mm to about 3 mm.

For example, the wood veneer can be secured to one surface of the core by an adhesive.

For example, the wood veneer can be secured to one surface of the core by a resin that includes polyurethane.

Referring to FIG. 3, a laminate diagram of a floorboard 30 is shown. The floorboard 30 has a core 31 of calcium carbonate and/or other materials as mentioned above, a first wood veneer 33 and a second wood veneer 35. The first wood veneer is secured to the surface of the core by a layer of resin 32. The second wood veneer is secured on top of the first wood veneer by a layer of resin 34.

For example, the resins 32 and 34 can be made of polyurethane resin.

Wood grain refers to the longitudinal direction of wood fibers.

For example, when the first wood veneer is fastened to the second wood veneer, the orientation of their respective grains can be a factor in stabilizing the warping of the floorboard.

For example, the first wood veneer may have a first grain direction.

For example, the first wood grain direction can be horizontal.

For example, the second wood veneer may have a second grain direction.

For example, the second grain direction can be vertical.

For example, the second wood veneer can be oriented at 90 degrees from the first grain direction of the first wood veneer.

For example, the first wood veneer and the second wood veneer can be the same type and thickness.

For example, it is understood that being of the same type means that the first wood veneer and the second wood veneer may be oak.

As another example, the first wood veneer and the second wood veneer can be maple.

For example, the second wood veneer can be fixed to the first wood veneer such that the first and second wood veneers form cross links that stabilize the warping of the floorboard.

For example, when the first wood veneer is fixed to the core, tension is generated in the first wood veneer in the direction of the first grain direction.

For example, this tension can force the first wood veneer to assume a curved shape when it is secured to the core.

For example, the tension can force the first wood veneer to curve.

For example, the tension can force the first wood veneer to curve vertically by approximately +5 mm.

For example, this tension can be created because wood can be hygroscopic.

For example, wood tends to absorb moisture from the air.

When the second wood veneer is secured onto the first wood veneer, a second tension is generated by the second wood veneer.

For example, this second tension can be in the second grain direction.

For example, this second tension can offset the tension generated by the first wood veneer.

For example, this second tension can be opposed to the first tension to reduce warping of the first wood veneer.

For example, assuming that the first wood veneer warps vertically by approximately +5 mm, the second tension can be applied to the first wood veneer to restrain the first wood veneer by -5 mm, thereby offsetting the warping of the floorboard.

For example, with such a configuration, the first wood veneer and the second wood veneer can form a cross link that stabilizes the warping of the floorboard.

For example, the first wood veneer and the second wood veneer can be two crossed wood veneer piles of the same type and thickness applied to an extruded core to stabilize the warp of the floorboard.

For example, the second wood veneer can be varnished.

For example, when the varnish is applied to the second wood veneer, it seals the second wood veneer.

For example, the varnish can be a sealer.

For example, the varnish can be applied to the second wood veneer to make the floorboard water resistant.

For example, the varnish can be applied to the second wood veneer to make the floorboard heat resistant.

For example, the varnish can be applied to the second wood veneer to make the floorboard moisture resistant.

For example, the varnish may include non-toxic, hypoallergenic materials.

For example, the varnish may contain an isocyanate.

For example, a color or pattern can be imparted to the varnish for aesthetic purposes.

Referring to FIG. 4, a laminate diagram of a floorboard 40 is shown. The floorboard 40 has a core 41 of calcium carbonate and/or other materials as mentioned above, a first wood veneer 43 and a second wood veneer 45. The first wood veneer is secured to the surface of the core by a layer of resin 42.

The second wood veneer is fixed onto the first wood veneer by a layer of resin 44.

For example, the resins 42 and 44 may be composed of polyurethane resin. The second wood veneer 45 may be coated with varnish 46.

For example, the varnish may include non-toxic, hypoallergenic materials.

For example, the varnish may contain an isocyanate.

For example, the varnish may include an anti-yellowing UV inhibitor.

For example, the varnish can provide increased resistance to surface abrasion.

For example, a floorboard may have at least 70% calcium carbonate and a first wood veneer having a first grain orientation, the first wood veneer secured to one surface of the core, and a second wood veneer having a second grain orientation secured to the first wood veneer such that the first and second wood veneers form cross links that stabilize the floorboard against warping, and the second veneer is varnished.

For example, the varnish may include non-toxic, hypoallergenic materials.

For example, the varnish may contain an isocyanate.

For example, the floorboards can be waterproof.

For example, the flooring may be moisture and/or heat resistant.

Referring to FIG. 5, a laminate diagram of a floorboard 140 is shown. The floorboard 140 has a core 141. The core may include calcium carbonate and/or other materials as described above. The floorboard 140 may further include a wood veneer 143. The wood veneer 143 may have a layer of varnish 146 applied to it.

For example, the core can be stable to humidity fluctuations (RH 30%-70%).

For example, the core may provide greater strength over time.

For example, it can be resistant to expansion and/or contraction, such as when atmospheric conditions change.

For example, the core can be heat resistant. For example, the core can be water resistant.

For example, the core can be rigid.

For example, the core can be dent-resistant.

For example, the wood veneer 143 can be secured to the surface of the core by an adhesive, such as a layer of resin.

For example, the resin may include polyurethane.

For example, the wood veneer can be multi-colored.

For example, the veneer can have a micro-v4 bevel.

For example, the veneer can have the authenticity and craftsmanship of real wood with its micro-v joints and evenly applied stain.

For example, the wood veneer 143 may comprise two pieces of wood veneer that are pre-fixed together.

For example, the wood veneer 143 may include two crossed wood veneer sheets of the same type and thickness.

For example, such a configuration can stabilize the warping of the floorboard.

For example, varnish 146 can be applied to the wood veneer 143.

For example, the varnish may include non-toxic, hypoallergenic materials.

For example, the varnish may contain an isocyanate.

For example, the varnish may have a non-toxic, hypoallergenic finish that incorporates an antimicrobial agent.

For example, the varnish may include an anti-yellowing UV inhibitor.

For example, the varnish can provide increased resistance to surface abrasion.

For example, the varnish can be durable.

For example, the varnish can perform well for a long period of time.

The method of making a floorboard may include processing the composition into the shape of a core, the core being made of calcium carbonate, and may include securing at least one wood veneer to one surface of the core.

For example, the processing step may include extruding the core.

For example, the core may further comprise PVC core resin, color powder, chlorinated polyethylene, polyethylene, and calcium stearate.

For example, the core can be extruded into a panel of at least 1230mm x 1280mm.

For example, the fastening step can include fastening a first wood veneer having a first grain orientation to one surface of the core, and fastening a second wood veneer having a second grain orientation onto the first wood veneer.

The method may further include applying a first resin layer between the one surface of the core and the first wood veneer to secure the first wood veneer to the core, and applying a second resin layer between the first wood veneer and the second wood veneer to secure the second wood veneer to the first wood veneer, thereby forming cross links between the first and second wood veneers that stabilize warping of the floorboard.

For example, the first resin layer and the second resin layer may contain polyurethane.

The method may further include the steps of trimming the board, cutting the board, profiling the board, sanding the board, and varnishing the board.

For example, profiling the floorboard may include profiling a longitudinal groove on one edge of the core and a longitudinal tongue on another edge of the core.

For example, profiling the floor plate may include profiling the click-lock design of each edge of the core.

For example, profiling the floorboard may include profiling an adhesive-free locking mechanism on each edge of the core.

For example, the varnish may include non-toxic, hypoallergenic materials.

For example, the varnish may include an isocyanate.

For example, the floor plate can be easily installed.

For example, the floor panels can be installed using a drop-lock installation.

For example, installation of the flooring may require no resin, nails, or staples.

For example, the flooring can be used in kitchens, bathrooms and basements.

For example, the floorboards can be installed over a subfloor even if they have minor imperfections.

For example, the present invention relates to a method of manufacturing boards that uses a variety of wood species on a calcium carbonate composite core to provide a rigid, waterproof hardwood flooring.

For example, the core can be greater than 3 mm and up to 8 mm thick.

For example, the core may be resistant to water, moisture and heat.

For example, the core provides a density ^of more than 1800 kg/ m3 .

For example, the heterochromatic composite core content provides greater than 70% calcium carbonate extruded into sheets or coupons of thickness greater than 0.5 mm to 4 mm and into panels greater than 1230 mm x 1280 mm for fixing wood veneers on their surfaces.

For example, the veneer resin includes polyurethane.

For example, the at least one wood veneer has a thickness of about 0.2 mm to about 7 mm.
For example, the at least one wood veneer has a thickness of about 0.5 mm to about 4 mm.
For example, the at least one wood veneer has a thickness of about 1 mm to about 3 mm.
For example, the at least one wood veneer has a thickness of about 0.5 mm to about 1 mm.

For example, the veneer can be impregnated through more than half of its thickness with a compatible polyurethane resin based on wood species absorbency that is applied with pressure and heat to one surface of the core after it has been extruded .

For example, two crossed wood veneers of the same type and thickness can be applied to one side of the extrusion to stabilize the warp of the panel. All components can be cut into boards, profiled, sanded, brushed, scraped and finally assembled to cover the surface of the panel, which is covered by a stain or natural water-based varnish containing isocyanates and impregnated into the other half of the thickness of the veneer to make it waterproof.

Due to its density and rigidity, the board can be profiled with a regular tongue and groove profile or a click-lock resinless system on each edge.

For example, this wood treatment on an inert, rigid core can make the board resistant to moisture or water absorption.

For example, the plate may be resistant to heat and thermal fluctuations.

For example, the plate may be resistant to expansion and/or contraction that results in peaks or gaps.

For example, the boards may have a swelling ratio, measured according to EN 13329, of less than about 0.5%/0.1 mm wood veneer thickness.
For example, the floorboards have a swelling ratio, measured according to EN 13329, of less than about 0.4%/0.1 mm thickness of wood veneer.
For example, the floorboards have a swelling ratio, measured according to EN 13329, of less than about 0.3/0.1 mm wood veneer thickness.
For example, the floorboards have a swelling ratio, measured according to EN 13329, of less than about 0.2/0.1 mm wood veneer thickness.
For example, the floorboards have a swelling ratio, measured according to EN 13329, of less than about 0.1/0.1 mm wood veneer thickness.

Although the present invention has been described with particular reference to specific embodiments, it will be understood that various modifications thereto will occur to those skilled in the art. The scope of the claims is not limited by the specific embodiments and examples provided in this disclosure and the accompanying drawings, but should be accorded the broadest interpretation consistent with the entire disclosure.

Claims (13)

A core (31, 41, 141) containing at least 50 wt. % calcium carbonate by weight;
A floorboard (1, 21, 30, 140) having a first grain orientation and a first wood veneer (33, 35, 43, 45, 143) fixed to one surface of said core (31, 41, 141),
A floorboard (1, 21, 30, 140) having a second grain orientation and comprising a second wood veneer (33, 35, 43, 45, 143) fixed onto said first wood veneer. The floorboard (1, 21, 30, 140) according to claim 1, wherein the first grain direction and the second grain direction are substantially perpendicular to each other. A core (31, 41, 141) containing at least 50 wt. % calcium carbonate by weight;
said first wood veneer (33, 35, 43, 45, 143) fixed to one surface of said core (31, 41, 141);
3. The floorboard (1, 21, 30, 140) of claim 1 or 2, wherein the first wood veneer (33, 35, 43, 45, 143) comprises about 55 to about 90% veneer resin (32, 34, 42, 44) by weight based on the total weight of the first wood veneer. A core (31, 41, 141) comprising at least 50 wt. % calcium carbonate, based on the total weight of the core (31, 41, 141), and at least 10 wt. % core resin, based on the total weight of the core (31, 41, 141);
said core (31, 41, 141) having a density of at least 1000 kg/m ³ ;
A floorboard (1, 21, 30, 140) according to any one of the preceding claims, comprising said first wood veneer (33, 35, 43, 45, 143) fixed to one surface of said core (31, 41, 141). The floorboard (1, 21, 30, 140) according to any one of claims 1 to 4, wherein the floorboard (1, 21, 30, 140) has a swelling ratio of less than about 0.4%/0.1 mm of wood veneer thickness as measured according to EN 13329. A floorboard (1, 21, 30, 140) as claimed in any one of claims 1 to 5, wherein a varnish (46, 146) is applied to the first wood veneer (33, 35, 43, 45, 143) such that the first wood veneer (33, 35, 43, 45, 143) is sandwiched between the core (31, 41, 141) and the varnish (46, 146). A floorboard (1, 21, 30, 140) according to any one of the preceding claims, wherein said first wood veneer (33, 35, 43, 45, 143) has a thickness of between about 0.2 mm and about 7 mm. A floorboard (1, 21, 30, 140) according to any one of the preceding claims, wherein the first wood veneer (33, 35, 43, 45, 143) is fixed to said one surface of the core (31, 41, 141) by means of an adhesive. The floorboard ( 1 , 21, 30, 140) according to any one of the preceding claims, wherein the core (31, 41, 141) forms a tongue and groove locking mechanism (23). A floorboard (1, 21, 30, 140) according to any one of the preceding claims, wherein the thickness of the core (31, 41, 141) is between about 1 mm and about 30 mm. The floorboard (1, 21, 30, 140) according to any one of the preceding claims, wherein the core (31, 41, 141) has a density of between about 1000 kg/ ^m3 and about 2600 kg/ ^m3 . 12. The floorboard (1, 21, 30, 140) of any one of the preceding claims, wherein the core (31, 41, 141) comprises between about 10 wt. % and about 40 wt. % of a core resin ( 32 , 34, 42, 44). A method for manufacturing a floorboard (1, 21, 30, 140) according to any one of claims 1 to 12 , comprising the steps of:
fixing a first wood veneer (33, 35, 43, 45, 143) having a first grain orientation to at least one surface of a core (31, 41, 141) comprising calcium carbonate and a core resin (32, 34, 42, 44);
and fixing a second wood veneer (33, 35, 43, 45, 143) having a second grain orientation over the first wood veneer (33, 35, 43, 45, 143).

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